Pallet system

ABSTRACT

A pallet system for the stacking and movement of a product, such as ammunition cans, is described. The pallet system includes vertical supports that substantially contribute to the strength and integrity of the pallet system. The pallet system allows for relatively rapid deployment of the pallet system&#39;s contents.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority and benefit from the U.S. Provisional Patent Application 63/270,400, filed Oct. 21, 2022 and titled, “PALLET SYSTEM,” which are incorporated herein by reference in their entirety for all purposes.

BACKGROUND

Pallets used for storage and movement of materials or items generally have a relatively low profile and a rectangular frame structure. A pallet supports products while being lifted by a forklift, a pallet jack, a front loader, a jacking device, or an erect crane. The pallet is the structural foundation of a unit load, comprising the pallet and its contained products, which are generally placed on the pallet and secured with strapping, stretch wrap or shrink wrap. A pallet with its unit load may be transported in large trucks, trailers, or aircraft, and stored in large warehouses or storage facilities.

Pallets may have a bottom designed to rest directly on the floor or ground and a top designed to accommodate stacking of multiple units of one or more products. While pallets are generally constructed from wooden slats, braces, plywood, or other sheet material, pallets can also be made of plastic, metal, and recycled materials.

Ammunition boxes, or ammo cans, are made for storing and transporting various calibers or types of ammunition. Most ammo cans are made of steel and include a rubber gasket around the lid to protect the contents from moisture and air when the lid is clamped shut. Generally being made for military use, ammo cans are relatively strong and sturdy. Standard sizes of some ammo cans are, in centimeters, 43×35.5×19, 45.5×15×25, 18.5×14.4×28, 26×16×9, and 30×17.5×8, just to list a few examples.

Ammo cans filled with ammunition are relatively heavy. A pallet for transporting ammo cans must be strong enough to endure large static and dynamic loads brought about by ammo cans stacked on the pallet. In addition to strength, design of a pallet may consider the ease at which ammo cans can be palletized and unpacked.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth with reference to the accompanying figures, in which the left-most digit of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items or features.

FIG. 1 is a perspective view of a loaded pallet system for storing or transporting a product, such as ammunition cans, according to various embodiments.

FIGS. 2A-2D are perspective views of a sequence of palletizing ammunition cans, according to some embodiments.

FIG. 3 is a perspective view illustrating a vertical support being inserted into a pallet system as part of a palletization process, according to various embodiments.

FIG. 4 is a perspective view illustrating a vertical support inserted and locked in place by a top tray of a pallet system, according to various embodiments.

FIG. 5 is a closeup perspective view illustrating a vertical support locked in place by a retaining region of a top tray of a pallet system, according to some embodiments.

FIG. 6 is a top view schematic diagram of a tray of a pallet system, according to some embodiments.

FIG. 7 is a flow diagram of a process for loading and assembling a pallet system, according to various embodiments.

DETAILED DESCRIPTION

Described herein are techniques and architectures for palletizing product units, such as ammunition canisters, hereinafter called ammo cans. Though examples herein are directed to product units being ammo cans, product units may be another entity that is to be stored or transported on pallets.

In some embodiments, a pallet system is used to hold ammo cans for storage and transportation. The pallet system includes vertical supports that substantially contribute to the strength and integrity of the pallet system. For example, individual filled ammo cans, though relatively small, are quite heavy. Accordingly, the aggregated weight of a load of multiple ammo cans arranged in stacked rows and columns, such as would be the case for palleted ammo cans, is very heavy. Such weight presents physical demands on the pallet system during transportation. For example, a pallet of ammo cans may be intentionally dropped from an aircraft (e.g., using a parachute) to the ground for supplying ammunition to users (e.g., soldiers). Even with the use of a parachute, an insufficiently robust pallet may hit the ground with an impact force that is enough to destroy the pallet and spill its contents. On the other hand, pallet system embodiments described herein include, among other things, vertical supports that, with various design features, substantially strengthen the pallet system so that it is able to withstand impact forces such as that mentioned above. Furthermore, the pallet system allows for relatively rapid deployment of the pallet system's contents. In other words, while increasing the strength of a pallet system generally leads to a configuration (e.g., additional wood members, increased banding, etc.) that prevents rapid access to its contents, this is not the case for the pallet system described herein.

FIG. 1 is a perspective view of a pallet system 100 for storing or transporting ammo cans, according to various embodiments. Pallet system 100 is illustrated as containing ammo cans 102 that are stacked in layers. Each such layer rests atop a tray, which may comprise plastic, metal, carbon fiber, polymer, or high-density plastic, just to name a few examples. The bottom layer of ammo cans rests on a bottom tray 104, which in turn rests upon a pallet 106. All other layers of ammo cans each rest on intermediate trays 108. Pallet system 100 includes a top tray 110, which may be slightly larger than the intermediate trays, and vertical supports 112 at each of the four corners of the pallet system. In some implementations, vertical supports 112 may be angle iron or other rigid material. As explained in detail below, in the assembled configuration of the pallet system, vertical supports 112 are secured and locked into place by the bottom, intermediate, and top trays. Banding straps 114 are placed in tension around the assembled pallet system. Banding straps, which are flexible and have high tensile strength, may be metal or plastic, for example. This tension provides vertical compression throughout the assembled pallet system. Though two banding straps are illustrated, another number of banding straps may be used and may be positioned in various parts of the perimeter of the assembled pallet system.

Though ammo cans are used as the example product, any of a number of other products could also be stored or transported by pallet system 100. Herein, ammo cans refer to a relatively robust, typically metal, container used to contain and store firearm ammunition. Ammo cans are available in a variety of sizes, having standardized dimensions. Ammo cans generally include a robust lid that is closed via a clamping mechanism. Because of the robust design of ammo cans, despite their heaviness, they can be stacked on top of one another, wherein the strength of the ammo cans are able to withstand the weight of overlaying ammo cans.

FIGS. 2A-2D are perspective views of a sequence of a process of palletizing ammunition cans, according to some embodiments. In FIG. 2A, a pallet 200 acts as a foundation on which a bottom tray 202 is placed. Bottom tray 202 comprises ridges 204 that are spaced apart in accordance with standardized sizes of ammo cans. In other words, ridges 204 are spaced apart so that a single row of ammo cans may fit therebetween. In some implementations, the bottom of each ridge 204 includes a horizontal lip, which is generally perpendicular to the predominantly vertical ridge. This lip may support at least a portion of the weight of the ammo cans (though pallet 200 underneath is present to support such weight). This horizontal lip, along with the vertical portion of the ridge, provides resistance to lateral (horizontal) shifting of the ammo cans. In other words, ridges 204 provide alignment and lateral stability to a layer of ammo cans resting upon bottom tray 202 (e.g., as illustrated in FIG. 2B).

Bottom tray 202 includes end members 206, to which ridges 204 are connected, and receiving portions 208 at each of the four corners. End members 206 may include an up-turned lip to keep ammo cans from sliding off the pallet. Accordingly, the distance between such up-turned lips on opposite ends of bottom tray 202 may be an integer multiple of the length of individual ammo cans (plus some tolerance to allow for minor size variations of the ammo cans and to avoid unreasonably tight packing).

Receiving portion 208 is configured to receive the bottom end of a vertical support, such as 112 of FIG. 1 . Receiving portion 208 may comprise a hole or a recessed region in a portion of bottom tray 202, or a small area at least partially surrounded by turned-up portions (e.g., lips) of bottom tray 202, just to name a few examples.

In some embodiments, pallet 200 includes openings 210, which are generally standard, for transport use via forklifts, etc.

In FIG. 2B, a layer 212 of ammo cans 214 are arranged in rows 216 and columns 218 atop bottom tray 202. Alignment of rows 216 of the ammo cans are maintained by ridges 204 of bottom tray 202.

In FIG. 2C, an intermediate tray 220 is placed upon layer 212 of the ammo cans. Intermediate tray 220 is similar to bottom tray 202 in that intermediate tray 220 comprises ridges to align ammo cans in rows thereon. In particular, ridges 222 are spaced apart, as in the case for ridges 204, in accordance with standardized sizes of ammo cans. In some implementations, the bottom of each ridge 222 includes a horizontal lip, which is generally perpendicular to the predominantly vertical ridge. This lip may support at least a portion of the weight of the ammo cans and may provide lateral strength to the ridge, while the vertical portion of the ridge provides resistance (e.g., such as sliding resistance) to lateral (horizontal) shifting of the ammo cans and helps establish and maintain positioning of intermediate tray 220. The weight of ammo cans 214, however, is predominantly supported by the ammo cans in the layer 212 below intermediate tray 220.

Intermediate tray 220 includes end members 224, to which ridges 222 are connected, and open portions 226 at each of the four corners. End members 224 may include an up-turned lip to keep ammo cans from sliding off the pallet. Accordingly, the distance between such up-turned lips on opposite ends of intermediate tray 220 may be the same or similar to that of the distance for end members 206.

Open portion 226 is configured to receive a vertical support, such as 112 of FIG. 1 . Open portion 226 may comprise a hole or a gap in a region of the connection between ridges 222 and end members 224 along the perimeter of intermediate tray, just to name a few examples.

FIG. 2D illustrates a completed pallet system 228 with a four-layer load (e.g., of ammo cans). Bottom tray 202 is disposed on pallet 200. Layer 212 of ammo cans 214 is resting upon bottom tray 202. Intermediate tray 220 is resting upon layer 212 of the ammo cans. A second layer 230 of ammo cans is resting upon intermediate tray 220. A second intermediate tray 232 is resting upon second layer 230. A third layer 234 of ammo cans is resting upon second intermediate tray 232. A third intermediate tray 236 is resting upon third layer 234. A fourth layer 238 of ammo cans is resting upon third intermediate tray 236. Such a sequence of alternating layers of cans and intermediate trays could continue, but in the example illustrated here, completed pallet system 228 comprises a load of four levels. Accordingly, after inserting vertical supports 240 at each of the four corners, a top tray 242 is placed upon fourth layer 238 of ammo cans (and on top of vertical supports 240). Note that a completed pallet system 228 may include two or more layers.

In some implementations, top tray 242 comprises ridges 244 spaced apart, as in the case for ridges 204 and 222, in accordance with standardized sizes of ammo cans. In some implementations, the top of each ridge 244 includes a horizontal lip, which is generally perpendicular to the predominantly vertical ridge. This lip may provide strength against vertical compressive forces presented by banding straps 246, described below. The vertical and horizontal portions of ridges 244 provide resistance to lateral (horizontal) shifting of the ammo cans and the vertical portion helps establish and maintain positioning of top tray 242.

Top tray 242 includes end members 246, to which ridges 244 are connected. At each of its four corners, top tray 242 includes a retaining region that essentially “caps off” and locks-in vertical supports 240. Insertion of vertical supports 240 comprises lowering them downward from above the topmost intermediate tray, inserting them into and through open portions 226 of all of the intermediate trays, and resting the bottom end of the vertical supports into and onto receiving portions 208 of bottom tray 202. Accordingly, retaining region of top tray 242, open portions 226 of all of the intermediate trays, and receiving portion 208 of bottom tray 202 all contribute to locking in each vertical support 240.

Finally, banding straps 248 are wrapped around the layers of ammo cans, trays, and an upper portion of pallet 200 and tightened. The tightened banding straps force top tray 242 downward in compression against the top layer (e.g., fourth layer 238) of ammo cans and the top of vertical supports 240. Banding straps 248, of which any number may be used, essentially squeeze together the multiple layers of ammo cans and trays, with the pallet, to form completed pallet system 228.

Among other things, vertical supports 240 contribute to the strength and overall integrity of completed pallet system 228. For example, vertical supports 240 protect the pallet system from sideways impacts and contribute to the pallet system strength for resisting burst or breaking failure from vertical impacts, such as during drops from aircraft. In some embodiments, vertical supports 240 carry at least a substantial portion of the weight imposed on top tray 242. Thus, this portion of weight (which may arise from anything resting atop completed pallet system 228 in addition to the force of compression from banding straps 248) may be transferred via vertical supports 240 onto bottom tray 202, and in turn, pallet 200.

FIG. 3 is a perspective view illustrating vertical support 240 being inserted during a process of establishing completed pallet system 228, according to various embodiments. Arrow 302 illustrates the direction of motion of vertical support 240.

The placement of vertical support 240 comprises, prior to introducing top tray 242, lowering the vertical support downward from above in the direction of arrow 302 and inserting it into and through open portions 226 of all of the intermediate trays (e.g., 236). Finally, the bottom end 304 of vertical support 240 is inserted into and onto receiving portion 208 of bottom tray 202. As mentioned above, receiving portion 208 may comprise a hole or a recessed region in a portion of bottom tray 202, or a small area at least partially surrounded by turned-up portions (e.g., lips) of bottom tray 202, just to name a few examples. In some implementations, a locking mechanism (not illustrated), located in a region at or near open portion 226 of one or more of the intermediate trays, may be used to secure vertical support 240 to the respective intermediate trays. For example, such a locking mechanism may comprise a pin or bolt that can be inserted into a hole in vertical support 240 and a corresponding hole in the intermediate tray. Thus, the inserted pin would essentially “tie” together the vertical support and the intermediate tray.

In designing for the tightness or tolerance of the fit between vertical support 240 and open portion 226 of the intermediate tray, consideration may be given to a trade-off between ease of sliding vertical support 240 through open portion 226 and the amount of lateral retention of vertical support 240 on the intermediate trays.

After placement of all vertical supports 240 (e.g., one at each of the four corners), top tray 242 is lowered onto the vertical supports and the top layer of ammo cans, as indicated by arrows 306. In particular, top tray 242 includes a retaining region 308 over every vertical support to lock-in the vertical supports. Such a retaining region may comprise a substantially flat corner portion of top tray 242 or any structural feature that can hold down vertical supports.

FIG. 4 is a perspective view illustrating, subsequent to the situation depicted in FIG. 3 , vertical support 240 inserted and locked in place by top tray 242, according to various embodiments. As illustrated, the vertical support has been lowered downward from above in the direction of arrow 302 and inserted into and through open portions 226 of all of the intermediate trays (e.g., 236). The bottom end (e.g., 304) of vertical support 240 has been inserted into and onto receiving portion 208 of bottom tray 202.

FIG. 5 is a closeup perspective view illustrating vertical support 240 locked in place by retaining portion 308 of top tray 242 of the pallet system, according to some embodiments. As mentioned above, top tray 242 includes retaining region 308 over every vertical support to lock-in the vertical supports. Such a retaining region may comprise a substantially flat corner portion of top tray 242 or any structural feature that can hold down vertical supports. Top tray 242 includes end members 246 to which ridges 244 are perpendicularly connected. In the example illustrated in FIG. 5 , end member 246 includes a bent or turned-down lip 502 and ridge 244 (e.g., the ridges on the perimeter of top tray 242) includes a bent or turned-down lip 504. Lips 502 and 504 may collectively form retaining region 308 of the top tray, such that retaining region 308 is able to retain, hold, and lock-in vertical support 240 when top tray 242 is placed thereon.

FIG. 6 is a top view schematic diagram of a tray 600 of a pallet system, according to some embodiments. As mentioned above, consideration of the size of standardized ammo cans is given to determining the spacings among ridges 602 and the lengths thereof. Tray 600 has features that are similar to or the same as those of a bottom tray, an intermediate tray, and a top tray. Most significant differences, however, are the corner regions 604 of tray 600. For example, if tray 600 is a bottom tray, then corner regions 604 will include a receiving region for receiving and supporting a vertical support. If tray 600 is an intermediate tray, then corner regions 604 will include an opening for receiving (and, in some cases, laterally supporting) a vertical support. If tray 600 is a top tray, then corner regions 604 will include a retaining region for retaining, holding, and locking-in a vertical support.

FIG. 7 is a flow diagram of a process 700 for palletizing a pallet system, such as 100, according to various embodiments. At 702, a bottom tray (e.g., 104) is placed on a pallet. At 704, a layer comprising rows and columns of ammo cans is placed atop the bottom tray. At 706, an intermediate tray (e.g., 108) is placed on the layer of ammo cans. At 708, subsequent layers of ammo cans are placed atop respective intermediate layers. At 710, vertical supports (e.g., 112) are inserted through corners of the intermediate trays and into the corners of the bottom tray. In some embodiments, vertical supports need not be located at corners of the pallet/tray system, but may be located elsewhere, such as mid-width of the pallet/trays, for example. At 712, a top tray (e.g., 110) is placed atop the vertical supports and the last-placed layer of ammo cans. At 714, banding straps (e.g., 114) are placed around trays and layers of ammo cans to place the system in compression with the pallet. In another embodiment, in addition to banding straps or as a replacement thereof, each vertical support may comprise a bolt on the top end and the top tray may have a mating hole (e.g., at the corners of the top tray). Engagement of the bolt with the hole (and a washer or two, for example) may allow for securing the top tray to the vertical supports. The bolt/hole combination may be recessed below the general plane of the top tray to allow for stacking of additional pallet system on top of the top tray. In the case for such a bolt system replacing banding straps, an additional bolt system may be placed at the bottom of the vertical supports to engage the pallet. In this fashion, the top tray may be secured to the pallet via the vertical supports.

CONCLUSION

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary forms of implementing the claims. 

1. A loaded pallet system comprising: a bottom tray comprising four first corners, wherein each of the first corners comprises a receiving region; a first set of rows of product units placed on the bottom tray; an intermediate tray placed on the first set of rows of product units and comprising four second corners, wherein the second corners are respectively aligned over the first corners, and wherein each of the second corners comprises an opening; a second set of rows of product units placed on the intermediate tray; a top tray placed on the second set of rows of product units and comprising four third corners, wherein the third corners are respectively aligned over the second corners, and wherein each of the third corners comprises a retaining region; and a vertical support member placed between the receiving region of the bottom tray and the retaining region of the top tray and penetrating the opening of the second corner.
 2. The loaded pallet system of claim 1, further comprising a banding strap that wraps around the bottom tray and the top tray to provide compressive forces on the bottom and top of the intermediate tray.
 3. The loaded pallet system of claim 1, further comprising a locking mechanism, located in a region at or near the opening of the intermediate tray, to secure the vertical support member to the intermediate tray. 4 The loaded pallet system of claim 1, wherein the product units are ammunition cans.
 5. A pallet system for storage and movement of at least one standard ammo can, the pallet system comprising: a bottom tray having a length and a width which substantially correspond to the length and width of the standard ammo can, the bottom tray having a series of linearly aligned parallel ridges formed therein, the bottom tray having a receiving portion substantially at or near each corner of the bottom tray; an intermediate tray having a length dimension and a width dimension which substantially correspond to the length and width of the standard ammo can, the intermediate tray having a series of linearly aligned parallel ridges formed therein, the intermediate tray having an opening substantially at or near each corner of the intermediate tray; a top tray having a length dimension and a width dimension which substantially correspond to the length and width of the standard ammo can, the top tray having a series of linearly aligned parallel ridges formed therein, the top tray having a retaining portion substantially at or near each corner of the top tray; and vertical support members substantially at or near the corners of, and substantially perpendicular to, the bottom, intermediate, and top trays, each support member i) inserted into the receiving portions of the bottom tray, ii) penetrating the receiving portions of the intermediate trays, and iii) at least partially covered by the retaining portions of the top tray.
 6. The pallet system of claim 5, wherein the receiving portion of the bottom tray comprises a lip or ridge of the edge of the bottom tray.
 7. The pallet system of claim 5, wherein the receiving portion of the intermediate tray comprises a hole or slot.
 8. The pallet system of claim 5, wherein the retaining portion of the top tray comprises a lip or ridge of the edge of the top tray.
 9. The pallet system of claim 5, further comprising banding straps that band the bottom tray and the top tray to provide compressive forces on the bottom and top of the intermediate tray.
 10. The pallet system of claim 5, wherein the retaining portions of the top tray are recessed below the plane of the top tray, and wherein the support posts comprise an end that includes a bolt to protrude through the recessed retaining portions of the top tray, and wherein a nut screwed onto the bolt locks the support post to the top tray.
 11. The pallet system of claim 5, wherein the support posts comprise angle iron. 